Portable power source

ABSTRACT

A portable power source. The portable power source includes a housing, a first battery pack support configured to receive a first removable and rechargeable battery pack, a second battery pack support configured to receive a second removable and rechargeable battery pack, an inverter within the housing, and an alternating current power outlet. The inverter is configured to receive output power from the first removable and rechargeable battery pack and the second removable and rechargeable battery pack. The inverter is configured to produce an alternating current power output. The alternating current power outlet is configured to receive the alternating current power output from the inverter. The inverter is configured to be disabled when the first removable and rechargeable battery pack is received in the first battery pack support and the second removable and rechargeable battery pack is not received in the second battery pack support.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 62/673,716, filed May 18, 2018, the entire content ofwhich is hereby incorporated by reference.

FIELD

The embodiments described herein relate to battery-powered portablepower sources and, more particularly, to such portable power sourcespowered by high-power battery packs.

SUMMARY

Users of power tools, outdoor tools, and other powered equipment utilizea wide range of corded, AC products every day. These products includelow- to high-powered tools and equipment, variable speed tools, andchargers for cordless batteries (referred to as “corded devices” or a“corded device”). These corded devices often do not have a suitablecordless option available. Even when cordless options are available,users may still prefer the corded devices, for example, due toadditional costs associated with cordless solutions, because the usersdo not believe that cordless solutions can provide the performance,run-time, etc., needed to complete heavier-duty applications, etc.

In some situations, power or sufficient power may not be available at aworksite, or available power may be unreliable or insufficient for thecorded device applications. Such scenarios may force the user to obtainpower from distant locations where reliable power is available (e.g.,through extension cords) or to utilize fuel-based power generators(which may be heavy and loud).

In some cases, the worksite may be enclosed or have inadequateventilation inhibiting use of a generator due to the emissions from thegenerator. In these situations, the user may need to run a longextension cord that can decrease the performance and life of the cordedAC products. This may result in decreases in productivity, continualinconvenience, an overall poor user experience, etc.

Accordingly, there may be a need for non-fuel based portable powersources that are reliable and can provide high power for extendedperiods of time for corded device applications.

In some independent aspects, a portable power source may be providedthat will go anywhere that corded device users work and power at least amajority of the corded devices they use. The users can, for example,eliminate long extension cords, increase the performance of their cordeddevices, easily move from one work area to another on-site, and,ultimately, be more productive. This use of a battery-powered powersource may shift perceptions of cordless capabilities, fuel progressionto a cordless jobsite, drive penetration and expansion of futurebattery-powered devices, changing the way users do their jobs.

In one independent aspect, a portable power source may generally includea housing defining a battery pack support, a power input (e.g., an ACpower input), and an AC power outlet. The portable power source mayfurther include a circuit supported by the housing and including aninput terminal on the battery pack support, an output terminal on thepower outlet, and an inverter electrically connected between the inputterminal and the output terminal. A battery pack may be supportable onthe battery pack support and electrically connectable to the circuit.The battery pack may include a battery pack housing supportable on thebattery pack support, at least one battery cell, and a battery terminalelectrically connected to the battery cell and electrically connectableto the input terminal, power being transferrable from the battery cellto the circuit to be output through the AC power outlet.

The portable power source may include multiple battery pack supports,each operable to support one of multiple battery packs, the supportedbattery packs being connected in series and operable to provide DC powerto the inverter. The circuit may include charging circuitry operable tocharge the multiple series-connected battery packs. The power input maybe used to charge the series-connected battery packs and to providepower to the AC power outlet. When power is not detected at the powerinput, the series-connected battery packs may provide power to theinverter to provide power to the AC power outlet.

Embodiments described herein provide a portable power source. Theportable power source includes a housing, a first battery pack supportconfigured to receive a first removable and rechargeable battery pack, asecond battery pack support configured to receive a second removable andrechargeable battery pack, an inverter within the housing, and analternating current power outlet. The inverter is configured to receiveoutput power from the first removable and rechargeable battery pack andthe second removable and rechargeable battery pack. The inverter isconfigured to produce an alternating current power output. Thealternating current power outlet is configured to receive thealternating current power output from the inverter. The inverter isconfigured to be disabled when the first removable and rechargeablebattery pack is received in the first battery pack support and thesecond removable and rechargeable battery pack is not received in thesecond battery pack support.

Embodiments described herein provide a portable power source. Theportable power source includes a housing, a first battery pack supportconfigured to receive a first removable and rechargeable battery pack, asecond battery pack support configured to receive a second removable andrechargeable battery pack, a third battery pack support configured toreceive a third removable and rechargeable battery pack, and a fourthbattery pack support configured to receive a fourth removable andrechargeable battery pack. The portable power source also includes aninverter within the housing and an alternating current power outlet. Theinverter is configured to receive output power from the first removableand rechargeable battery pack, the second removable and rechargeablebattery pack, the third removable and rechargeable battery pack, and thefourth removable and rechargeable battery pack. The inverter isconfigured to produce an alternating current power output. Thealternating current power outlet is configured to receive thealternating current power output from the inverter. The inverter isconfigured to be disabled when the first removable and rechargeablebattery pack is received in the first battery pack support, the secondremovable and rechargeable battery pack is received in the secondbattery pack support, the third removable and rechargeable battery packis received in the third battery pack support, and the fourth removableand rechargeable battery pack is not received in the fourth battery packsupport.

Embodiments described herein provide a portable power source. Theportable power source includes a housing, a first battery pack supportconfigured to receive a first removable and rechargeable battery pack, asecond battery pack support configured to receive a second removable andrechargeable battery pack, a third battery pack support configured toreceive a third removable and rechargeable battery pack, and a fourthbattery pack support configured to receive a fourth removable andrechargeable battery pack. The portable power source also includes aninverter within the housing, an alternating current power outlet, and auser interface. The inverter is configured to receive output power fromthe first removable and rechargeable battery pack, the second removableand rechargeable battery pack, the third removable and rechargeablebattery pack, and the fourth removable and rechargeable battery pack.The inverter is configured to produce an alternating current poweroutput. The alternating current power outlet is configured to receivethe alternating current power output from the inverter. The userinterface includes a fuel gauge. The fuel gauge is configured to displayinformation associated with at least one of the first removable andrechargeable battery pack, the second removable and rechargeable batterypack, the third removable and rechargeable battery pack, and the fourthremovable and rechargeable battery pack. The fuel gauge is alsoconfigured to display an indication corresponding to which of the atleast one of the first removable and rechargeable battery pack, thesecond removable and rechargeable battery pack, the third removable andrechargeable battery pack, and the fourth removable and rechargeablebattery pack the information is associated.

Before any independent embodiments of the are explained in detail, it isto be understood that the embodiments described herein are not limitedin their application to the details of construction and the arrangementof components set forth in the following description or illustrated inthe following drawings. Embodiments are capable of being practiced or ofbeing carried out in various ways. Also, it is to be understood that thephraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting.

Use of “including” and “comprising” and variations thereof as usedherein is meant to encompass the items listed thereafter and equivalentsthereof as well as additional items. Use of “consisting of” andvariations thereof as used herein is meant to encompass only the itemslisted thereafter and equivalents thereof. Also, the functionalitydescribed herein as being performed by one component may be performed bymultiple components in a distributed manner. Likewise, functionalityperformed by multiple components may be consolidated and performed by asingle component. Similarly, a component described as performingparticular functionality may also perform additional functionality notdescribed herein. For example, a device or structure that is“configured” in a certain way is configured in at least that way but mayalso be configured in ways that are not listed.

Furthermore, some embodiments described herein may include one or moreelectronic processors configured to perform the described functionalityby executing instructions stored in non-transitory, computer-readablemedium. Similarly, embodiments described herein may be implemented asnon-transitory, computer-readable medium storing instructions executableby one or more electronic processors to perform the describedfunctionality. As used in the present application, “non-transitorycomputer-readable medium” comprises all computer-readable media but doesnot consist of a transitory, propagating signal. Accordingly,non-transitory computer-readable medium may include, for example, a harddisk, a CD-ROM, an optical storage device, a magnetic storage device, aROM (Read Only Memory), a RAM (Random Access Memory), register memory, aprocessor cache, or any combination thereof.

Many of the modules and logical structures described are capable ofbeing implemented in software executed by a microprocessor or a similardevice or of being implemented in hardware using a variety of componentsincluding, for example, application specific integrated circuits(“ASICs”). Terms like “controller” and “module” may include or refer toboth hardware and/or software. Capitalized terms conform to commonpractices and help correlate the description with the coding examples,equations, and/or drawings. However, no specific meaning is implied orshould be inferred simply due to the use of capitalization. Thus, theclaims should not be limited to the specific examples or terminology orto any specific hardware or software implementation or combination ofsoftware or hardware.

Other independent aspects of the embodiments described herein may becomeapparent by consideration of the detailed description and accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a portable power source, such as abattery-powered portable power source, with battery packs attached,according to embodiments described herein.

FIG. 1B is a perspective view of the portable power source of FIG. 1A,illustrated with no battery packs.

FIG. 1C is a top view of the portable power source of FIG. 1A.

FIG. 1D is a front view of the portable power source of FIG. 1A.

FIG. 1E is a rear view of the portable power source of FIG. 1A.

FIG. 1F is a side view of the portable power source of FIG. 1A.

FIG. 1G is another side view of the portable power source of FIG. 1A.

FIG. 1H is a bottom view of the portable power source of FIG. 1A.

FIG. 1I is a perspective view of the portable power source of FIG. 1A.

FIG. 1J is a perspective view of the portable power source of FIG. 1A,illustrating removal or insertion of a battery pack.

FIG. 1K is a perspective view of the portable power source of FIG. 1with a battery pack removed.

FIG. 1L is a top view of the portable power source of FIG. 1 with anumber of battery packs removed.

FIG. 2 is a perspective view of a battery pack to power the portablepower source of FIG. 1, according to embodiments described herein.

FIGS. 3A, 3B, 3C, 3D, 3E, and 3F illustrate a user interface on thefront of the portable power source, according to embodiments describedherein.

FIGS. 4A and 4B illustrate a spring-loaded interface for battery packconnection, according to embodiments described herein.

FIG. 5 is a top view of the portable power source in FIG. 1, accordingto embodiments described herein.

FIGS. 6A, 6B, 6C, 6D, and 6E illustrate operation of the portable powersource of FIG. 1, according to embodiments described herein.

FIG. 7 is a diagram of the circuitry for powering the battery packs andcontrolling the inverter, according to embodiments described herein.

FIG. 8 illustrates a lock interface of the portable power source of FIG.1, according to embodiments described herein.

FIG. 9A is a perspective view of a portable power source including ahandle in a closed position, according to embodiments described herein.

FIG. 9B is a perspective view of a portable power source including ahandle in an open position, according to embodiments described herein.

FIG. 9C is a cross-sectional view of the handle of FIG. 9A in the closedposition.

FIG. 9D is a cross-sectional view of the handle of FIG. 9B in the openposition.

FIG. 10A illustrates a lockable handle for a portable power source,according to embodiments described herein.

FIG. 10B illustrates the lockable handle of FIG. 10A in a lockedposition.

FIG. 10C illustrates the lockable handle of FIG. 10A in an unlockedposition.

FIG. 10D illustrates the lockable handle of FIG. 10A in an unlocked andopen position.

FIG. 10E illustrates the lockable handle of FIG. 10A being held in theunlocked and open position using a padlock.

FIG. 10F is a cross-sectional view of the lockable handle of FIG. 10A inunlocked and open position.

DETAILED DESCRIPTION

FIGS. 1A-1L show a portable power source 10 powered by one or moreseries-connected battery packs 14 (e.g., four battery packs 14A, 14B,14C, 14D shown) and operable to power different corded devices, such aspower tools, outdoor tools, other powered equipment (e.g., lights,chargers for cordless batteries, etc.). As discussed below in moredetail, the portable power source 10 may be operated with fewer than theavailable battery packs 14 (e.g., with only three of the four batterypacks 14 operational and/or electrically connected to the portable powersource 10). The portable power source 10 may be operational only whencertain ones of the battery packs 14 are operational and/or electricallyconnected to the portable power source 10.

The illustrated portable power source 10 includes a housing 18 having atop 22, a bottom 26, a front 30, a rear 34, and opposite sides 38, 42.For each battery pack 14, a battery pack support 46 (four in theillustrated construction) is provided on the housing 18. In theillustrated construction, a first battery pack support 46A supports afirst battery pack 14A, a second battery pack support 46B supports asecond battery pack 14B, and, so on, for the battery pack supports 46C,46D and the associated battery packs 14C, 14D.

A frame 50 is connected to the housing 18. A handle 54 is connected toportions of the frame 50, and the handle 54 may include elastomericmaterial to improve gripping, comfort of a user during movement of theportable power source 10, etc. Rubber feet may be fixed on a bottom ofthe housing 18 (e.g., covering the corners), on the frame 50, etc. Thefeet provide a non-slip, non-scratch surface when the portable powersource 10 is placed on a surface, such as a floor at a work site.

Each battery pack 14 includes a housing 17 (see FIG. 2) supporting anumber of battery cells (not shown). Battery pack terminals 15electrically connect the battery cells to the portable power source 10.The battery pack terminals 15 may include power terminals operable totransfer power between the battery pack 14 and the portable power source10 and communication terminals operable to transmit information betweenthe battery pack 14 and the portable power source 10.

The battery packs 14 includes one or more cells arranged in cellstrings, each having a number of battery cells (e.g., five batterycells) connected in series to provide a desired output discharge voltage(e.g., a nominal voltage [e.g., 12 V, 18 V, 20 V, 24 V, 40 V, 60 V, 80V, 120 V, etc.] and current capacity). The battery packs 14 may includea number of cell strings connected in parallel (e.g., a single cellstring “5S1P”, two cell strings “5S2P”, three cell strings “5S3P”,etc.). In other embodiments, other combinations (series, parallel,combination series-parallel configurations) of battery cells are alsopossible.

Each battery cell may have a nominal voltage between 3 V and 5 V and anominal capacity between about 3 Ah and about 5 Ah or more (e.g., up toabout 9 Ah). The battery cells may be any rechargeable battery cellchemistry type, such as, for example Lithium (“Li”), Lithium-ion(“Li-ion”), other Lithium-based chemistry, Nickel-Cadmium (“NiCd”),Nickel-metal Hydride (“NiMH)”, etc. Similar battery packs 14 aredescribed and illustrated in U.S. Patent Application Publication No.2019/0044110, filed Jul. 25, 2018 (previously filed as U.S. ProvisionalPatent Application No. 62/536,807, filed Jul. 25, 2017, and U.S.Provisional Patent Application No. 62/570,828, filed Oct. 11, 2017), allentitled “HIGH-POWER BATTERY-POWERED SYSTEM,” the entire contents of allthree of which are hereby incorporated by reference.

FIGS. 3A-3F illustrate a user interface 70 provided on the front 30 ofthe housing 18. In the illustrated examples, the user interface 70includes a power button 74, AC outlets 78, USB outlets 82,over-condition indicators 86, a wireless connection indicator 90, apower input 94 (e.g., an AC power input), and fuel gauges 98A-98F.

The power button 74 may be implemented as a pushbutton, a two-wayswitch, a touch button, etc. The power button 74 is used to controlpower output to the user interface 70 and can be activated to turn theportable power source 10 ON or OFF. When the power button 74 is used toturn ON the portable power source 10, power output through the ACoutlets 78 and USB outlets 82 are enabled and thus the fuel gauge 98 andthe over-condition indicators 86 are activated to display indications.When the power button 74 is used to turn OFF the portable power source10, power output through the AC outlets 78 and USB outlets 82 isdisabled and the fuel gauge 98 and the over-condition indicators 86 aredeactivated.

The AC outlets 78 are, for example, 15 A, 120 V AC outlets that providea similar power output as a wall outlet. The AC outlets 126 are poweredby the battery packs 14. In the illustrated example, the over-conditionsindicators 86 include an over-temperature indicator 102 and an overloadindicator 106. The over-temperature indicator 102 is activated when atemperature of the portable power source 10 or the battery packs 14exceeds a predetermined temperature threshold. The overload indicator106 is activated when a load output of the portable power source 10exceeds a predetermined load threshold.

The wireless connection indicator 90 indicates whether the portablepower source 10 is wirelessly-connected to a remote device (e.g., asmartphone or other user device). The AC input 94 may include aretractable or removable cable that can be plugged into an externalpower source (e.g., a 15 A, 120 V wall outlet). The AC input 94 is usedto supply power to charge the battery packs 14 supported on the portablepower source 10. When connected to an external power source, theportable power source 10 may pass through AC power to the AC outlets 78in addition to charging the supported battery pack(s) 14.

The fuel gauge 98 indicates the state-of-charge of the associatedbattery pack(s) 14. FIG. 3A illustrates a fuel gauge 98A operable todisplay information (e.g., the remaining state-of-charge [“SOC”], thepower level, etc.) of the lowest-charged battery pack 14 withoutidentifying which battery pack 14 is being displayed. The illustratedfuel gauge 98A may be similar to the fuel gauge on a correspondingelectrical device (e.g., a drill) and similar battery packs.

FIG. 3B illustrates a fuel gauge 98B displaying an additional level ofinformation (e.g., identifying which battery pack 14 is beingdisplayed). FIG. 3C illustrates a fuel gauge 98C displaying a locationof the battery pack 14 corresponding to the location on the portablepower source 10. FIG. 3D illustrates a fuel gauge 98D displaying batterylife as an estimate of remaining charge of the battery pack 14. FIG. 3Eillustrates a fuel gauge 98E which identifies the lowest charged batterypack 14, and the user can check the battery level on the fuel gauge ofthat battery pack 14. FIG. 3F illustrates a fuel gauge 98F whichidentifies the lowest-charged battery pack 14 with a ranking of thebattery packs.

With reference to FIG. 4A, one or more of the battery pack supports 46may include a spring-loaded interface 110 for connection of a batterypack 14. In some constructions, all of the battery pack supports 46include spring-loaded interfaces 110. In other constructions, fewer thanall of the battery pack supports 46 (e.g., three of the battery packsupports 46) include a spring-loaded interface 110. The spring-loadedinterface 110 includes a spring 114, contact block 118, contacts 122, acontact sliding lever 126, and terminals 130 for connection to a batterypack 14. The terminals 130 are electrically connectable to the terminals15 of the battery pack 14. The terminals 130 include power terminals 134(e.g., positive and negative power terminals 138, 142) for powertransfer between the battery pack 14 and the portable power source 10.Communication terminals 146 on the interface 110 facilitatecommunication (e.g., transmission of signals, information, etc.) betweenthe battery pack 14 and the portable power source 10. Communication mayinclude information such as a temperature, a state-of-charge, anidentification, etc., of the battery pack 14.

The interface 110 is movable relative to the housing 18 between aretracted, connected position, when a battery pack 14 is connected andan extended, disconnected position, when a battery pack 14 is notconnected. In the retracted, connected position, as a battery pack 14 isinserted onto the interface 110, the contact sliding lever 126 is pushedback, and the spring 114 is compressed, causing the contacts 122 tocreate an electrical connection with the contact block 118 and allowingcurrent to flow between the installed battery pack 14 to the portablepower source 10. In the extended, disconnected position, as the batterypack 14 is removed from or is not installed on the interface 110, theelectrical connection is severed (see FIG. 4B), stopping or preventingcurrent flow. In the extended, disconnected position, the circuit of theportable power source 10 is also severed, such that no power will beprovided from the battery packs 14 to the AC output 78 until theelectrical connection is restored.

As described above, in some constructions, all battery pack supports 46include a spring-loaded interface 110. In such constructions, a batterypack 14 is installed on each and every one of the battery pack supports46 to connect the circuit of the portable power source 10 so that powermay be supplied from the battery packs 14 to the AC output 78. In otherconstructions (see FIGS. 5-6E), the portable power source 10 includes an“optional” battery pack support 46 in which a battery pack 14 is notrequired to be installed and/or operational for operation of theportable power source 10. In other words, the circuit of the portablepower source 10 is connected even without the battery pack 14 supported(or being operational) on the optional battery pack support 46.Installation of a battery pack 14 on the optional battery pack support14 may complete the circuit of the portable power source 10 through thebattery pack 14, rather than through a circuit portion of the optionalbattery pack support 46. An identification of the optional battery packsupport 46 (e.g., “OPTIONAL”) identifies the battery pack support 46 toa user.

When a battery pack 14 is removed (see FIG. 6A) or is not operational(see FIG. 6C), the portable power source 10 may stop working. When thebattery packs 14 are arranged or re-arranged so that the optionalbattery pack support 46 is open (without a battery pack 14 supported oroperational), the portable power source 10 may be operated again. In theconstruction of FIG. 6B, when a battery pack 14 is removed from theoptional battery pack support 46, the portable power source 10 continuesto be operational. In other constructions (see FIGS. 6D-6E), the batterypack supports 46 do not include spring-loaded interfaces 110. In theillustrated constructions, the portable power source 10 is operationalwith any one of the battery packs 14 not installed (FIG. 6D) or notoperational (FIG. 6E).

FIG. 7 illustrates circuitry 150 for the portable power source 10. Theillustrated circuitry 150 is operational for charging the battery packs14A-14D and powering the inverter 154. The illustrated circuitry 150connects the battery packs 14 in series to supply power (e.g., about 80V DC input) through the inverter 154 to an external electrical device(e.g., 120 V AC). The circuitry 150 includes separate charging circuitportions 158 for charging the respective series-connected battery packs14. An AC detect circuit 162 is operable to detect an AC input 94 andincludes an optocoupler 166. A battery wake up circuit 170 includes aplurality of switches 174 and optocouplers 167 and 168. The circuitry150 also includes an inverter power switch 178 and the AC output 78 forproviding AC power to external corded electrical devices. A plurality ofdiodes 182 provide isolation for the battery packs 14 and preventnegative voltages from damaging the optocouplers.

The charging circuit portions 158 provide charging current for therespective battery packs 14 if AC power is provided at the AC input 94.While the battery packs 14 are connected in series to supply power tothe inverter 154, each pair of a battery pack 14 and its associatedcharging circuit portion 158 operate independently of the other pairs.The inputs of the charging circuit portions 158 are electricallyconnected in parallel with the AC input 94 while the outputs of thecharging circuit portions 158 are isolated from the AC input 94.

In the illustrated construction, the inverter 154 includes an electronicprocessor (not shown) operable to control operation of the inverter 154.The inverter 154 is turned off and does not provide power to the ACoutlet 78 when AC power is provided at the AC input 94. The AC detectcircuit 162 is monitored until AC power is no longer provided at the ACinput 94. If AC power is not provided at the AC input 94, the transistorof the optocoupler 166 is turned on, and the inverter 154 monitorsV_(in) and the inverter power switch 178. If the inverter power switch178 is off, then the inverter 154 remains in a power sleep state. If theinverter power switch 178 is on, the inverter 154 monitors V_(in) (thevoltage provided by the battery packs 14) for a voltage above a certainlevel (e.g., at least about 62 V). If V_(in) (the voltage provided bythe battery packs 14) is at or above the level (e.g., at or above 62volts), the inverter 154 transmits a battery wake up signal and monitorsthe inverter enable node.

The battery wake up signal includes a voltage pulse transmitted to theLED portion of the optocouplers 167 simultaneously, causing thetransistors of the optocouplers 167 to turn on and applying respectivevoltages to the battery packs 14 to wake the battery packs 14. In otherconfigurations, the battery wake up signal is not transmittedsimultaneously to the optocouplers 167; instead, each optocoupler 167 isdriven independently (e.g., by the inverter controller).

Upon successful wake up of battery packs 14A-14D, switches 174 areturned on, which causes the optocouplers 168 to turn on and drive theinverter enable signal high. In other configurations, each optocoupler168 outputs an individual signal to be monitored by the invertercontroller. Upon receiving the inverter enable signal(s), the inverter154 is activated to provide 120 V AC power at the AC output 78. If atany point V_(in) falls below a particular level (e.g., 62 V), theinverter power switch 178 turns off, or the AC detect goes low, theinverter 154 returns to a power sleep state.

The DC and DP lines for each battery pack 14 include an optocoupler toisolate the voltages and to act as a switch. In such a construction,current cannot travel to the inverter enable line until all of theoptocouplers are powered with sufficient voltage (e.g., 12 V). All ofthe DC lines are effectively “AND”-gated to provide a single signal tothe inverter controller. Likewise, a single signal from the invertercontroller is split to each of the battery DP lines for communicationback to each battery pack 14.

In the illustrated construction, the DC signal from each battery pack 14is used to control the inverter controller with respect to low batteryvoltage. In other constructions (not shown), the portable power source10 includes monitoring circuitry, components, etc. configured for theinverter controller to monitor (e.g., directly) the voltage of thebattery pack(s) 14.

With reference to FIG. 8, a battery lock point 62 is provided for abattery pack support 46. A padlock (not shown) may be installed at thebattery lock point 62 to prevent the associated battery pack 14 frombeing detached from the battery pack support 46. When installed, eachpadlock may extend into and block the removal path of an associatedbattery pack 14. Additionally or alternatively, the installed padlockmay interfere with operation of an associated battery latch mechanism(described below) to prevent removal of the battery pack 14. Additionallock points, for example a padlocked cover (not shown), may be providedon the front 30 of the housing 18 to prevent access to components of theportable power source 10 (e.g., to prevent access to the electricaloutlets).

FIGS. 9A-9D illustrate a portable power source 200. The portable powersource 200 includes a housing 204, a first frame member 208, a secondframe member 212, a first handle support member 216, a second handlesupport member 220, and a handle 224. The handle 224 extends between andperpendicularly with respect to the first handle support member 216 andthe second handle support member 220. FIG. 9A illustrates the handle 224in a closed position. When the handle 224 is in the closed position, theportable power source 200 is capable of receiving a battery pack in eachof a plurality of battery pack supports (see FIG. 1C for a similarportable power source with four battery packs 14A-14D connected to fourbattery pack supports 46A-46D, respectively). FIG. 9B illustrates thehandle 224 in an open position. When the handle 224 is in the openposition, the first handle support member 216 and the second handlesupport member 220 are moved with respect to one another to increase adistance between the first handle support member 216 and the secondhandle support member 220. In some embodiments, both the first handlesupport member 216 and the second handle support member 220 are movable.In other embodiments, only one of the first handle support member 216and the second handle support member 220 is movable.

Moving the handle 224 between the closed position and the open positioncauses the first handle support member 216 and the second handle supportmember 220 to function as lock or retention members for one or morebattery packs (e.g., battery packs 14-A-14D). For example, FIG. 9Cillustrates a cross-sectional view of the handle 224 in relation to thehousing 204 of the portable power source 200. A first aperture 228 and asecond aperture 232 function as guides for the movement of the firsthandle support member 216 and the second handle support member 220. Thefirst aperture 228 and second aperture 232 receive a portion of thesecond handle support member 220 and the first handle support member216, respectively, to allow the first handle support member 216 and thesecond handle support member 220 to move or slide with respect to oneanother. The first aperture 228 and the second aperture 232 areillustrated in FIG. 9C with respect to the first frame member 208.Corresponding first and second apertures are similarly included on thesecond frame member 212.

The handle portion 224 includes in internal rod or member 236 that isenclosed within the handle portion 224 when the handle portion 224 is inthe closed position. The member 236 includes an aperture or lockreceiving portion 240. As shown in FIG. 9C, when the handle 224 is inthe closed position, the first handle support member 216 and secondhandle support member 220 are at their shortest distance apart, and thedistance is shorter in length than the width of the housing 204. As aresult, the portable power source 200 is capable of receiving a batterypack in each of a plurality of battery pack supports (see FIG. 1C for asimilar portable power source with four battery packs 14A-14D connectedto four battery pack supports 46A-46D, respectively). However, as shownin FIG. 9D, when the handle 224 is in the open position, the firsthandle support member 216 and second handle support member 220 arefurther apart. The length of the combination of the first handle supportmember 216, the second handle support member 220, and the handle 224 islonger than when the handle 224 is in the closed position and isapproximately the same length as the width of the housing 204. As aresult, the portable power source 200 is either incapable of receiving abattery pack in each of a plurality of battery pack supports or anybattery packs connected to the battery pack supports are prevented frombeing removed. As such, the first handle support member 216 and thesecond handle support member 220 are configured as mechanical interlocksthat can be used to physically prevent a battery pack from beingconnected to or removed from the portable power source 200. A padlock orsimilar locking mechanism can be inserted into the aperture 240 to holdthe handle 224 in the open position.

FIGS. 10A-10F illustrate a portable power source 300. The portable powersource 300 includes a housing 304, a first frame member 308, a secondframe member 312, a first handle support member 316, a second handlesupport member 320, and a handle 324. The handle 324 extends between andperpendicularly with respect to the first handle support member 316 andthe second handle support member 320. FIG. 10A illustrates the handle324 in a closed position. When the handle 324 is in the closed position,the portable power source 300 is capable of receiving a battery pack ineach of a plurality of battery pack supports (see FIG. 1C for a similarportable power source with four battery packs 14A-14D connected to fourbattery pack supports 46A-46D, respectively). The handle 324 alsoincludes a locked position 328 and an unlocked position 332. The handle324 is illustrated in the locked position 328 in FIG. 10B. To enter thelocked position 328, the handle 324 is rotated with respect to thesecond handle support member 320 such that the handle 324 prevents thefirst handle support member 316 and the second handle support member 320from moving with respect to one another. In the locked position 328, thehandle 324 forms a rigid structure with the first handle support member316 and the second handle support member 320. The handle 324 isillustrated in the unlocked position 332 in FIG. 10C. To enter theunlocked position 332, the handle 324 is rotated with respect to thesecond handle support member 320 such that the handle 324 permits thefirst handle support member 316 and the second handle support member 320to move with respect to one another. In the unlocked position 332, thehandle 324 is able to be moved from the closed position (see FIG. 10A)to an open position.

FIG. 10D illustrates the handle 324 in the open position. When thehandle 324 is in the open position, the first handle support member 316and the second handle support member 320 move with respect to oneanother to increase a distance between the first handle support member316 and the second handle support member 320. In some embodiments, boththe first handle support member 316 and the second handle support member320 are movable. In other embodiments, only one of the first handlesupport member 316 and the second handle support member 320 is movable.As shown in FIG. 10D, the handle 324 includes an internal rod or member336 that is extended out of the handle 324 when the handle portion is inthe open position. The member 336 is enclosed within the handle 324 whenthe handle 324 is in the closed position (see FIG. 10A).

In some embodiments, moving the handle 324 between the closed positionand the open position causes the first handle support member 316 and thesecond handle support member 320 to function as lock or retentionmembers for one or more battery packs (e.g., battery packs 14A-14D)similar to the manner illustrated in FIGS. 9C and 9D. In suchembodiments, the first handle support member 316 and the second handlesupport member 320 are configured as mechanical interlocks that can beused to physically prevent a battery pack from being connected to orremoved from the portable power source 300.

FIG. 10D illustrates the portable power source 300 including a firstaperture 340 and a second aperture 344 that function as guides for themovement of the first handle support member 316 and the second handlesupport member 320. The first aperture 340 and second aperture 344receive a portion of the second handle support member 320 and the firsthandle support member 316, respectively, to allow the first handlesupport member 316 and the second handle support member 320 to move orslide with respect to one another. The first aperture 340 and the secondaperture 344 are illustrated in FIG. 10D with respect to the secondframe member 312. Corresponding first and second apertures are similarlyincluded on the first frame member 308. As also illustrated in FIG. 10D,the member 336 includes an aperture or lock receiving portion 348. Asillustrated in FIG. 10E, a padlock 352 or similar locking mechanism canbe inserted into the aperture 348 to hold the handle 324 in the openposition.

FIG. 10F illustrates a cross-sectional view of the handle 324 in theopen position. The handle 324 includes projections 356 on the member336. The projections 356 on the member 336 can be received in apertures360 and 364 when the handle 324 is in the closed position. A resilientor bias member (e.g., a spring) 368 is included within the handle 324.In some embodiments, the resilient member 368 biases the handle 324 intothe locked position 328. In other embodiments, the resilient member 368biases the handle 324 into the unlocked position 332. Regardless of themanner in which the resilient member 368 biases the handle 324, theprojections 356 can be received in the apertures 360, 364 and the handle324 can be rotated. By rotating the handle 324, the handle 324 can beheld in either the locked position 328 or the unlocked position 332(e.g., by respective grooves within the apertures 360, 364 that receiveprotections 356 for countering the force from the resilient member 368).

In some embodiments, the peak power output of the portable power source10, 200, 300 with all battery packs 14 (e.g., four “5S2P” battery packs14) is within a range of about 3000 W to about 4000 W (e.g., 3400 W) fora short period of time of between about 2 s and about 4 s (e.g., 3 s).In such configurations, the portable power source 10, 200, 300 canprovide a peak output power of about 3600 W for at least about 3.5 s.

In some embodiments, the sustained or continuous maximum output power ofthe portable power source 10, 200, 300 with all battery packs 14 iswithin a range of about 1500 W to about 2000 W. In some embodiments, thesustained or continuous maximum output power is about 1800 W. A runtimeat maximum output power for the portable power source 10, 200, 300 withall battery packs 14 is within a range of about 18 minutes to about 21minutes (e.g., about 20.5 minutes).

In some embodiments, the peak power output of the portable power source10, 200, 300 with optional battery pack support(s) without anoperational battery pack 14 (e.g., with three “5S2P” battery packs 14)is within a range of about 3000 W to about 4000 W (e.g., 3400 W) for ashort period of time of between about 2 s and about 4 s (e.g., 3 s). Insuch configurations, the portable power source 10, 200, 300 can providea peak output power of about 3600 W for at least about 3.5 s.

In some embodiments, the sustained or continuous maximum output power ofthe portable power source 10, 200, 300 with optional battery packsupport(s) without an operational battery pack 14 (e.g., with threebattery packs 14) is within a range of about 1500 W to about 2000 W. Insome embodiments, the sustained or continuous maximum output power isabout 1800 W. A runtime at maximum output power for the portable powersource 10, 200, 300 with all battery packs 14 is within a range of about18 minutes to about 21 minutes (e.g., about 20.5 minutes).

The portable power source 10, 200, 300 is operable with differentconfigurations of battery packs 14. With “5S1P” battery pack(s) 14, theoutput power and/or the run time of the portable power source 10, 200,300 is reduced when compared to the “5S2P” battery packs 14. When “5S3P”battery packs 14 are used, the output power and/or the run time of theportable power source 10, 200, 300 is increased when compared to the“5S2P” battery packs 14.

The portable power source 10, 200, 300 may be operable to provide avariable output. The output (e.g., the maximum continuous output power,maximum peak output power, etc.) of the portable power source 10, 200,300 may be adjusted based on the number of operable battery packs 14connected to the portable power source 10, 200, 300. For example, withthe maximum (four) battery packs 14, the portable power source 10, 200,300 may have a maximum continuous output power of about 1600 W to about2700 W. With fewer battery packs 14, the portable power source 10, 200,300 may be operated to limit the maximum continuous output power—about1200 W to about 2000 W with three battery packs 14, about 800 W to about1350 W with two battery packs 14, about 400 W to about 700 W with onebattery pack 14. In some embodiments, a maximum peak output power of theportable power source 10, 200, 300 is approximately 3600 W over a shortperiod of time (e.g., approximately 3 to 5 seconds) when three or fourbattery packs 14 are connected to the portable power source 10, 200,300. In other embodiments, the maximum peak output power of the portablepower source 10, 200, 300 over a short period of time (e.g.,approximately 3 to 5 seconds) is between 3000 W and 4200 W.

Variable output of the portable power source 10, 200, 300 may beachieved in various ways. For example, the portable power source 10,200, 300 may be configured with parallel-connected battery packs 14electrically connected to parallel-connected, in-phase inverters (e.g.,four 400 W inverters connected in parallel). In another example, theinput voltage of the battery pack(s) 14 may be provided to a singleinverter with a controlled (e.g., electrically controlled) output.

Thus, the embodiments described herein may provide, among other things,a battery-powered portable power source. Although certain preferredembodiments have been described in detail, variations and modificationsexist within the scope and spirit of one or more independent aspects ofthe embodiments described herein.

One or more independent features and/or independent advantages of theembodiments described herein are set forth in the following claims.

What is claimed is:
 1. A portable power source comprising: a housing; afirst battery pack support configured to receive a first removable andrechargeable battery pack; a second battery pack support configured toreceive a second removable and rechargeable battery pack; an inverterwithin the housing, the inverter configured to receive output power fromthe first removable and rechargeable battery pack and the secondremovable and rechargeable battery pack, the inverter configured toproduce an alternating current power output; and an alternating currentpower outlet configured to receive the alternating current power outputfrom the inverter, wherein the inverter is configured to be disabledwhen the first removable and rechargeable battery pack is received inthe first battery pack support and the second removable and rechargeablebattery pack is not received in the second battery pack support, andwherein the inverter is configured to be enabled when the firstremovable and rechargeable battery pack is not received in the firstbattery pack support and the second removable and rechargeable batterypack is received in the second battery pack support.
 2. The portablepower source of claim 1, further comprising: a third battery packsupport configured to receive a third removable and rechargeable batterypack; and a fourth battery pack support configured to receive a fourthremovable and rechargeable battery pack.
 3. The portable power source ofclaim 2, wherein the inverter is configured to be enabled when the firstremovable and rechargeable battery pack is not received in the firstbattery pack support, the second removable and rechargeable battery packis received in the second battery pack support, the third removable andrechargeable battery pack is received in the third battery pack support,and the fourth removable and rechargeable battery pack is received inthe fourth battery pack support, wherein the inverter is configured tobe disabled when the first removable and rechargeable battery pack isreceived in the first battery pack support, the second removable andrechargeable battery pack is received in the second battery packsupport, the third removable and rechargeable battery pack is notreceived in the third battery pack support, and the fourth removable andrechargeable battery pack is received in the fourth battery packsupport.
 4. The portable power source of claim 1, further comprising afirst handle support member, a second handle support member, and ahandle.
 5. The portable power source of claim 4, wherein the handleincludes an open position and a closed position.
 6. The portable powersource of claim 5, wherein, when the handle is in the closed position,the first removable and rechargeable battery pack is able to be removedfrom the first battery pack support.
 7. The portable power source ofclaim 6, wherein, when the handle is in the open position, the firstremovable and rechargeable battery pack is prevented from being removedfrom the first battery pack support.
 8. The portable power source ofclaim 4, wherein the handle is rotatable between a locked position wherethe first handle support member and the second handle support member arenot movable with respect to one another, and an unlocked position wherethe first handle support member and the second handle support member aremovable with respect to one another.
 9. The portable power source ofclaim 1, further comprising: a user interface that includes: a directcurrent power outlet, the alternating current power outlet, and one ormore indicators.
 10. The portable power source of claim 9, wherein theone or more indicators include a wireless connection indicator.
 11. Theportable power source of claim 9, wherein the user interface furtherincludes a fuel gauge associated with the first removable andrechargeable battery pack and the second removable and rechargeablebattery pack.
 12. The portable power source of claim 1, wherein thefirst battery pack support includes an interface movable with respect tothe housing between an extended position and a retracted position. 13.The portable power source of claim 1, wherein a maximum continuousoutput power of the portable power source is between approximately 1600W and approximately 2700 W.
 14. The portable power source of claim 1,wherein a maximum peak output power of the portable power source isbetween approximately 3000 W and approximately 4200 W.
 15. A portablepower source comprising: a housing; a first battery pack supportconfigured to receive a first removable and rechargeable battery pack; asecond battery pack support configured to receive a second removable andrechargeable battery pack; a third battery pack support configured toreceive a third removable and rechargeable battery pack; a fourthbattery pack support configured to receive a fourth removable andrechargeable battery pack; an inverter within the housing, the inverterconfigured to receive output power from the first removable andrechargeable battery pack, the second removable and rechargeable batterypack, the third removable and rechargeable battery pack, and the fourthremovable and rechargeable battery pack, the inverter configured toproduce an alternating current power output; and an alternating currentpower outlet configured to receive the alternating current power outputfrom the inverter, wherein the inverter is configured to be disabledwhen the first removable and rechargeable battery pack is received inthe first battery pack support, the second removable and rechargeablebattery pack is received in the second battery pack support, the thirdremovable and rechargeable battery pack is received in the third batterypack support, and the fourth removable and rechargeable battery pack isnot received in the fourth battery pack support, wherein the inverter isconfigured to be enabled when the first removable and rechargeablebattery pack is not received in the first battery pack support, thesecond removable and rechargeable battery pack is received in the secondbattery pack support, the third removable and rechargeable battery packis received in the third battery pack support, and the fourth removableand rechargeable battery pack is received in the fourth battery packsupport.
 16. The portable power source of claim 15, further comprising:a user interface that includes: the alternating current power outlet,and one or more indicators.
 17. The portable power source of claim 16,wherein the one or more indicators include a wireless connectionindicator.
 18. The portable power source of claim 15, further comprisinga handle that includes an open position and a closed position, wherein,when the handle is in the open position, the first removable andrechargeable battery pack is prevented from being removed from the firstbattery pack support.
 19. A portable power source comprising: a housing;a first battery pack support configured to receive a first removable andrechargeable battery pack; a second battery pack support configured toreceive a second removable and rechargeable battery pack; a thirdbattery pack support configured to receive a third removable andrechargeable battery pack; a fourth battery pack support configured toreceive a fourth removable and rechargeable battery pack; an inverterwithin the housing, the inverter configured to receive output power fromthe first removable and rechargeable battery pack, the second removableand rechargeable battery pack, the third removable and rechargeablebattery pack, and the fourth removable and rechargeable battery pack,the inverter configured to produce an alternating current power output;an alternating current power outlet configured to receive thealternating current power output from the inverter; and a user interfacethat includes a fuel gauge, the fuel gauge configured to displayinformation associated with at least one of the first removable andrechargeable battery pack, the second removable and rechargeable batterypack, the third removable and rechargeable battery pack, and the fourthremovable and rechargeable battery pack, and display an indicationcorresponding to which of the at least one of the first removable andrechargeable battery pack, the second removable and rechargeable batterypack, the third removable and rechargeable battery pack, and the fourthremovable and rechargeable battery pack the information is associated.20. The portable power source of claim 19, wherein the inverter isconfigured to be enabled when the first removable and rechargeablebattery pack is received in the first battery pack support, the secondremovable and rechargeable battery pack is received in the secondbattery pack support, the third removable and rechargeable battery packis received in the third battery pack support, and the fourth removableand rechargeable battery pack is not received in the fourth battery packsupport.
 21. The portable power source of claim 19, wherein the userinterface includes a wireless connection indicator.
 22. The portablepower source of claim 19, further comprising a handle that includes anopen position and a closed position, wherein, when the handle is in theopen position, the first removable and rechargeable battery pack isprevented from being removed from the first battery pack support.